System and method for three-dimensional (3D) computer-aided manufacturing (CAM) of an ensemble of pilot equipment and garments

ABSTRACT

A system comprising a scanner to scan the airman or soldier (subject), a processor to receive, from the scanner, a non-manifold three-dimensional (3D) digital surface model (DSM) scan data representative of the subject, and a computer-aided manufacturing (CAM) device. The processor recognizes anatomical features on the 3D surface model including the cephalic (head) region of the scanned subject; stores each sub region defined by anatomical features as a non-manifold 3D surface model; creates a surface offset from the DSM sub region; creates a closed volume within and between the DSM sub region and the offset surface representative of a solid 3D pilot flight equipment; and causes a computer-aided manufacturing (CAM) device to manufacture the solid 3D pilot flight equipment.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/840,795, filed Apr. 6, 2020, the contents of which are incorporatedherein in their entirety by reference.

BACKGROUND

Embodiments relate to a system and method for three-dimensional (3D)computer-aided manufacturing (CAM) of an ensemble of equipment andgarments for soldiers and airmen.

Extracting tailoring measurements or anthropometric data from 3D scansis seeing rapid adoption in retail for applications such as virtualtry-on, custom clothing, and online sizing.

Meanwhile, military applications, have not seen widespread adoption andwould benefit greatly from these improved systems. Complex militarysystems have low error tolerances and commonly require “perfection” tofit wearable equipment, but rely heavily upon manual tailormeasurements, standard size rolls, and disjointed systems; resulting ina fit process that is labor and time intensive, subject to error.

SUMMARY

Embodiments relate to a system and method for three-dimensional (3D)computer-aided manufacturing (CAM) of an ensemble of equipment andgarments for soldiers and airmen. A system comprising a scanner to scanthe airman or soldier (subject), including at least the head of thesubject; and a computing device having at least one processor andtangible, non-transitory computer readable medium having programinstructions which when executed to cause at least one processor to:receive, from the scanner, digital three-dimensional (3D) digitalsurface model (DSM) scan data representative of the surface of thesubject in a computational geometry format. The at least one processorfurther to: recognize anatomical features on the 3D surface modelincluding the cephalic (head) region of the scanned subject; store eachsub region defined by anatomical features as a non-manifold 3D surfacemodel; create a surface offset from the DSM sub region; create a closedvolume within and between the DSM sub region and the offset surfacerepresentative of a solid 3D pilot flight equipment; and cause acomputer-aided manufacturing (CAM) device to manufacture the solid 3Dpilot flight equipment based on the formed digital data representativeof the solid 3D pilot flight equipment.

A method comprising: receiving, from a scanner device, a digitalthree-dimensional (3D) digital surface model (DSM) scan datarepresentative of the surface of the subject in a computational geometryformat. The at least one processor further to: recognize anatomicalfeatures on the 3D surface model including the cephalic (head) region ofthe scanned subject; store each sub region defined by anatomicalfeatures as a non-manifold 3D surface model; create a surface offsetfrom the DSM sub region; create a closed volume within and between theDSM sub region and the offset surface representative of a solid 3D pilotflight equipment; and cause a computer-aided manufacturing (CAM) deviceto manufacture the solid 3D pilot flight equipment based on the formeddigital data representative of the solid 3D pilot flight equipment.

BRIEF DESCRIPTION OF THE DRAWINGS

A more particular description briefly stated above will be rendered byreference to specific embodiments thereof that are illustrated in theappended drawings. Understanding that these drawings depict only typicalembodiments and are not therefore to be considered to be limiting of itsscope, the embodiments will be described and explained with additionalspecificity and detail through the use of the accompanying drawings inwhich:

FIG. 1 illustrates a block diagram of a system for three-dimensional(3D) computer-aided manufacturing (CAM) of pilot flight equipment and/orflight suit;

FIG. 2A illustrates a flow diagram of a method for customized pilotflight equipment (PFE) for a flight suit ensemble;

FIG. 2B illustrates a flight suit ensemble with PFE;

FIG. 3A illustrates a system architecture of the pilot flight equipmentand suit customizer (PFE&SC) module;

FIG. 3B illustrates the Helmet Liner(s) Customizer Module;

FIG. 4 illustrates a graphical user interface for selecting pilot flightequipment;

FIG. 5A illustrates first helmet liner;

FIG. 5B illustrates a second helmet liner;

FIG. 5C illustrates a side view of a pilot helmet with visor and oxygenmask;

FIG. 6 illustrates a flowchart of a method for manufacturing amade-to-fit helmet liner;

FIG. 7A illustrates a representative mesh of a side view of athree-dimensional head and face of a subject;

FIG. 7B illustrates a representative mesh of an isometric perspectiveview of the three-dimensional head and face of the subject;

FIG. 8A illustrates a boundary for a helmet liner on the side view ofthe head and face of FIG. 7A;

FIG. 8B illustrates a boundary for a helmet liner on the perspectiveview of the head and face of FIG. 7B;

FIG. 9 illustrates a first mesh of the head of the subject for a helmetliner;

FIG. 10A illustrates a hidden line view of the helmet on a subject;

FIG. 10B illustrates a section-view of the helmet and helmet linerlayers;

FIG. 11 illustrates a first mesh with oxygen mask landmark pointsdepicted for generating an oxygen mask;

FIG. 12 illustrates a graphical user interface for selecting flight suitgarments;

FIG. 13 illustrates a special purposes computer system.

DETAILED DESCRIPTION

Embodiments are described herein with reference to the attached figureswherein like reference numerals are used throughout the figures todesignate similar or equivalent elements. The figures are not drawn toscale and they are provided merely to illustrate aspects disclosedherein. Several disclosed aspects are described below with reference tonon-limiting example applications for illustration. It should beunderstood that numerous specific details, relationships, and methodsare set forth to provide a full understanding of the embodimentsdisclosed herein. One having ordinary skill in the relevant art,however, will readily recognize that the disclosed embodiments can bepracticed without one or more of the specific details or with othermethods. In other instances, well-known structures or operations are notshown in detail to avoid obscuring aspects disclosed herein. Theembodiments are not limited by the illustrated ordering of acts orevents, as some acts may occur in different orders and/or concurrentlywith other acts or events. Furthermore, not all illustrated acts orevents are required to implement a methodology in accordance with theembodiments.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope are approximations, the numerical values set forth inspecific non-limiting examples are reported as precisely as possible.Any numerical value, however, inherently contains certain errorsnecessarily resulting from the standard deviation found in theirrespective testing measurements. Moreover, all ranges disclosed hereinare to be understood to encompass any and all sub-ranges subsumedtherein. For example, a range of “less than 10” can include any and allsub-ranges between (and including) the minimum value of zero and themaximum value of 10, that is, any and all sub-ranges having a minimumvalue of equal to or greater than zero and a maximum value of equal toor less than 10, e.g., 1 to 4.

FIG. 1 illustrates a block diagram of a system 100 for three-dimensional(3D) computer-aided manufacturing (CAM) of pilot flight equipment (PFE)and/or pilot garments. The system 100 may comprise a digital scanner 110configured to scan the anatomy or anatomy part of a subject 10. Thesystem 100 may include a pilot flight equipment and suit customizer(PFE&SC) module 120. The PFE&SC module 120 may be a computer programproduct stored on tangible and non-transitory computer readable medium,the computer program product when executed cause the generation of pilotflight equipment and/or suit. The pilot flight equipment (PFE) may bemade of a homogeneous material, in some embodiments. By way ofnon-limiting example, the homogeneous material may be a chemical mixturewhich is configured to be used in an additive manufacturing process. Forexample, the homogeneous material may be a polyurethane resin, such asfor protective helmet lining and padding. Parts of the PFE may be madeof non-homogeneous materials or multiple homogeneous material sectionsintegrated into a single part.

The PFE&SC module 120 may include program instructions stored in acomputer readable medium which when executed to cause the at least oneprocessor of computing device 150 to: receive, from the scanner, digitalthree-dimensional (3D) surface model scan data representative of theanatomy or anatomy part of a subject 110. The scan data may be in astereolithography (STL), OBJ, a point cloud format, or similarcomputational geometry format. The processor of the PFE&SC module 120systematically studies the scan data from the scanner to determine keyfeatures and uses these features to create non-manifold regions ofinterest along the surface of the scanned subject. By way of anon-limiting example, a region of interest is the face of the subject,particularly the region encompassing the mouth and nose for use indesigning a custom pilot's oxygen mask. The scan data's computationalgeometry for these non-manifold surface regions of interest may bethickened to create a closed volume (solid 3D model). The processor ofthe PFE&SC module 120 may cause computer-aided manufacturing (CAM)device to manufacture a solid 3D pilot flight equipment device from thesolid 3D model. For example, the PFE may be a helmet liner based on theformed data representative of the solid 3D model. Further, the PFE&SCmodule 120 may cause the CAM device to manufacture flight suit garments.

The scanned data may be used to develop measurement values for varioussub regions such as the neck and arm to determine a neck size and armlength for use in defining interconnecting cables worn on, or attachedto, the subject or pilot suit. Still further, the measurement values areused by the processor to select the nearest fit from available sizes foreach article of the subject's garment and supply recommendedalterations. Other sub regions may include the face, for making a customoxygen mask (landmark points visible in FIGS. 7A, 7B and 11 ), and thebrow, crown, nape, and ear for making custom helmet liners (shown inFIGS. 7A to 10B) that match the contour of the head and regions of thetorso and legs for making custom body armor.

The system 100 may include a computer-aided manufacturing (CAM) machine140A configured, by computer aid, to manufacture a three-dimensional(3D) custom pilot flight equipment. By way of a non-limiting example,this pilot flight equipment may be a custom helmet protective liner(s).In some embodiments, the liners may be constructed of differentmaterials, which are layered to improve performance.

In some embodiments, the system 100 may include a pilot suit CAMdevice(s) 140B. Each CAM device may be dedicated for a 3D printingoperation of a particular component of the ensemble. For example, CAMdevice 140B may be used for printing articles of the pilot's flightsuit, like a close-fitting thermal protective layer.

The digital scanner 110 may use digital scanning technology configuredto collect thousands to millions of data points to make a digital map ofthe subject or part of the anatomy of a subject. The digital scanner 110may be configured to scan and create a digital model of a subject'sone-of-a-kind head. The digital scanner 110 may be a peripheral deviceinterfaced with the computing device 150. In some embodiments, thedigital scanner 110 may be remote from the computing device 150 andinclude its own processor and program code instructions. Digital scanner110 may employ non-contact sensor technology of one of: infrared,optical, structured light, or laser.

By way of non-limiting example, the digital scanner 110 may include aplurality of scanning devices 112 with integral sensors. The sensors maybe one of infrared, optical, structured light, or laser device. Thescanner 110 may be a non-contact system. The scanning may have a scantime of <10 seconds.

The computing device 150 may communicate with a remote computing device155 such as for tailoring certain pilot equipment and garments based onthe scan of the subject.

FIG. 2A illustrates a flow diagram of a method 200A for customized pilotflight equipment (PFE) and flight suit ensemble, as shown in FIG. 2B.The method 200A may include scanning the pilot, at block 202A; andprocessing the scanned data points of the scanned data file, at block204A. At block 206A, the method may include determining PFE measurementsbased on the data points for customizing lengths and sizes of standard,non-custom, garments and equipment. For example, the measurement may beuseful in defining the length for an electronics or communications cableor the oxygen hose. Further, the measurements may be useful indetermining the flight jacket size for the pilot from standard sizes; byway of a non-limiting example, standard sizes may include small, medium,large, and extra-large.

The method 200A may include, at block 208A, conducting a fit analysisusing the measurements collected, at block 206A, against the non-customflight suit garments and pilot flight equipment. The results of the fitanalysis, at block 208A may be used for sizing and tailoring, at block210A. The method 200A may print the size, length of interconnectingcables, and routine tailor alterations (e.g., hemming to a printedinseam length) based on the measurements obtained, at block 206A, andfit analysis performed, at block 208A.

The method 200A when customizing the ensemble may manufacture certainarticles such as, without limitation, helmet liner(s), protectiveclothing, and oxygen mask. The method 200A may include creating at leastone standard triangle language (STL) file, at block 216A, for use indesigning these custom PFE and flight suit articles. For example, eachof the helmet liner(s) may require an STL file of the brow and crownregions of the scanned subject's head or cephalic. The oxygen mask mayrequire its own STL file of the front of the subject's face includingmouth, nose, check bones, etc.

The method 200A, at block 218A, may include designing the pilot flightequipment (PFE) and flight suit based on the corresponding STL file. Theoxygen mask would be customized based on the subject's face, thebreathing supply source hose, and the helmet's interconnectingrequirements. The helmet's liner(s) would be customized and optimizedbased on the helmet size, the helmet type, and the head of the subject.

The method 200A, at block 220A, may perform computer-aided manufacturing(CAM) of the custom PFE and flight suit articles. By way of non-limitingexample, the CAM of the PFE would include manufacturing the helmetliner(s), close-fitting thermal protective layer, and/or oxygen mask.The CAM may include 3D printing. The method 200A, at block 222A, mayinclude assembly and fit of the manufactured articles. For example, thehelmet liner(s) would be affixed to the interior of the helmet;exhalation valve(s), supply hose, and hardware would be affixed to theoxygen mask.

In some embodiments, the CAM oxygen mask would include fastener pointsto affix connectors to the mask wherein the connectors are used toconnect the mask to the helmet. However, the PFE whether trimmed to sizefrom a standard size or additively manufactured from the scan data wouldbe made-to-fit the pilot based on the scanned pilot.

FIG. 2B illustrates a flight suit ensemble with PFE. The PFE may includehelmet 215 which may be available in a plurality of sizes. By way ofnon-limiting example, helmets 215 may be available as small, medium andlarge. The measurements such as the size of the cranium of the subjectmay be used to determine the size of the helmet from which to beginpatterning of the liners.

The oxygen mask 230 may be customized for the facial features of thesubject relative to the helmet, as will be described in more detail. Theoxygen mask hose 235 may be customized, in length, based on thesubject's anatomy. The oxygen mask hose 235 may be a function ofmeasurements such as length of the torso so that the pilot can receivethe oxygen gas from the oxygen gas source, cockpit size, and seatlocation so that the hose 235 may reach the oxygen gas source.

The interconnecting cable 245 may be customized based on the scan of thesubject. The cable 245 may be a function of measurements such as lengthof the torso, cockpit size, and seat location so that the cable 245 cantransmit communications, video, or other critical data from the pilot'sflight equipment to the aircraft.

The flight suit 250 may include at least a coverall 252 as an outerlayer and a flight jacket 254. Other layers may be under the coveralland thus not shown in this illustration.

Measurements from the scan data may be defined by the InternationalOrganization of Standardization (ISO), for example. The ISO standardizedmeasurement may be used for sizing standards. Examples of ISO standardsinclude ISO 8559-1:2017, Size Designation of Clothes Part 1; ISO8559-2:2017, Size Designation of Clothes Part 2; and ISO 8559-2:2018,Size Designation of Clothes Part 3: Methodology for the creation ofmeasurement table and intervals. Various standards for common materialsused in the finished product(s) include MIL-C-83141A, MIL-V-43511,MIL-C-83409, MIL-W-4088/PIA-W-4088—Nylon Webbing, MIL-DTL-5038K(Mil-T-5038)/PIA-T-5038—Nylon Tape, MIL-T-87130—Kevlar Tape/Webbing,MIL-W-5625/PIA-W-5625—Nylon Tubular, MIL-T-5608/PIA-T-5608-NylonParachute Tape, MIL-T-6134C—Nylon Parachute Tape, MIL-W-17337—NylonWebbing, MIL-W-27657B—Nylon Webbing, MIL-W-43668C—Textured NylonWebbing, MIL-W-43685B—Nomex Tape, MIL-T-43709B—Nomex Tape, andMIL-W-87127—Kevlar Tape. The term “MIL” as used herein stands for U.S.military standards.

Other standards include ISO 7250-1:2017, Basic human body measurementsfor technological design—Part 1: Body measurement definitions andlandmarks; and ISO 20685-1:2018 3D scanning methodologies forinternationally compatible anthropometric databases—Part 1: Evaluationprotocol for body dimensions extracted from 3-D body scans.

FIG. 3A illustrates a block diagram of the pilot flight equipment andsuit customizer (PFE&SC) module 120. The PFE&SC module 120 may include ahelmet liner(s) customizer module 320 and/or an oxygen mask customizermodule 322. The PFE&SC module 120 may include a protective layer module324. The PFE&SC module 120 may include an electronic cable customizermodule 326. The PFE&SC module 120 may include a pilot flight suitcustomizer module 328.

FIG. 3B illustrates a block diagram of the helmet liner(s) customizermodule 320. The operation of the helmet liner(s) customizer module 320will be described in relation to FIG. 3B in combination with FIGS. 6,7A, 7B, 8A, 8B and 9 .

In FIGS. 7A and 7B, triangulated mesh of vertices is generated by thegeometry generator module 330. By way of a non-limiting example, thescanners may use an iterative closest point algorithm to match thepoints detected by each sensor. This results in a mapped 3D geometrypoint cloud of the subject's surfaces exposed to the sensors of thescanning devices 112. From here, various meshing algorithms may be usedto create a manifold surface from the scanned pilot. For example, aDelaunay Triangulation method may be used on all the points (vertices)to join them together into a mesh. This mesh, typically stored in aStereolithography (STL) format, is generated in module 330.

FIG. 6 illustrates a flowchart of a process for manufacturing amade-to-fit helmet liner. The blocks of the process 600 may be performedin the order shown or a different order. One or more of the blocks maybe performed contemporaneously. The module may include additional blocksand some blocks may be deleted or skipped.

The process 600 may include, at block 605, recognizing attributes and/orfeatures, by the feature recognition module 332. In the case of thehelmet liner customizer module 320, the features may include the ear724, brow 710, nape 714, and other anatomical features of the head shownin FIGS. 7A and 7B. These are used to section off a region of themanifold surface generated in module 330. As shown in FIGS. 8A and 8B,the edges or boundaries denoted by the reference numerals PA1-PAX andPB1-PBX are in close proximity to the features identified in FIGS. 7Aand 7B, at block 605.

The method 600 may include, at block 606, identifying the boundaryextrema point vertices (i.e., points PA1-PAX) of the 3D surface model,by the boundary locator module 332. The identifying, at block 606, maybe performed by the customizer module 320. The method 600 may determinethe extrema boundary, at block 606, which become the free edge of a newnon-manifold 3D digital model surface after trimming at block 607. Thisnew surface is a sub-region representing an area of the pilot's headthat will be in contact with the finished helmet liner; this is asub-region of the STL generated in geometry generator module 330. Thesteps in block 605 thru block 608, in other embodiments, may not occurin the sequence shown in FIG. 6 . With the lower surface of the linerdefined, at block 606, and stored as a new STL at block 607,measurements from the scan data may be used to determine the helmetsize, at block 608. The helmet size can be used to select a helmetcandidate based on a fit analysis of the head dimensions or measurementswith the known dimensions of an off-the-shelf helmet candidate. Theliner thickness may also be determined at block 608. A closed volume ofthe liner from the 3D surface model may be generated at block 608.

Assume that the head has a circular profile which can be measured todetermine a diameter. The diameter D of the crown 712 may be used todetermine the size of the helmet, for example. FIG. 7B illustrates arepresentative mesh 700B of isometric view of the three-dimensional headand face of the subject with diameter D. Some embodiments may also usecircumference to select the helmet size from among the standard sizesavailable for a given aircraft. By way of a non-limiting example, theaircraft system also has defined requirements for the location of thepilot's head within the helmet so that the electronics are properlyaligned in operation. These requirements allow the alignment of theselected helmet size to the scanned pilot as shown in FIG. 10A.

FIG. 10A illustrates a helmet outline 1015 overlaid on a cranium of asubject's scanned image representation. Assume for the purposes ofdiscussion FIG. 10A illustrates a determined helmet size suitable to fitthe head of the subject. The helmet size accommodates a helmet liner(s)of thicknesses T. FIG. 10B illustrates a section-view of the helmetliner(s) of thickness T. Layer 1060 represents space for an outermostliner which may be supplied to fit the helmet size selected beforeassembling in custom layers. The layer denoted by reference numerals1005 and 1010 represents a custom brow and a custom crown, respectively.An innermost liner 1050 in contact with the pilot's head is also shown.This thickness of the custom brow 1005 and custom crown 1010 may beapplied to the liner sub-region surface to create a solid volume 3Dmodel with inner surface contact the scanned pilot and outer surfacecontacting the helmet.

Referring again to FIG. 3B, the helmet liner customizer module 320 mayinclude a boundary generator module 334. The boundary generator module334 may determine the contour of the helmet candidate for determiningthe helmet liners such as the first helmet liner 500A and/or the secondhelmet liner 500B. The helmet liner customizer module 320 may includeattachment generator module 336. The attachments at block 614 may bedesigned to interface the interior surface of the helmet shell to thehelmet liner(s). The helmet interfaces are well known in the art andvary per helmet type. In some embodiments, a helmet liner covering onlythe brow may be separate from the helmet liner covering the crown suchthat together they form a complete helmet liner layer which isconfigured to be in direct contact with the pilot's head. Another linerlayer, 1060 (FIG. 10B), may be configured to interface between thehelmet inner surface and the brow and crown liner(s). In someembodiments the brow and crown liner portions may be integrated into asingle liner. These are defined in block 610 and affect boundary module334. The finished 3D liner model may then be sent to a CAM formanufacturing. At block 614, feature templates are imported, andinternal and/or external features are added to the liners. In otherwords, the computational geometry is updated with the added internaland/or external features. The helmet liner customizer module 320 mayinclude helmet liner geometry generator module 338. At block 616, a datafile is generated representative of a solid (closed volume) 3D helmetliner in the form of the helmet liner geometry. At block 618, the CAMmachine is caused to create a solid 3D helmet line from the file.

FIG. 8A illustrates a point boundary for a helmet liner on the side viewof the head and face of FIG. 7A. FIG. 8B illustrates a point boundaryfor a helmet liner on the perspective view of the head and face of FIG.7B. The lower extrema points PA1-PAX are shown in FIG. 8A. Similarly,the extrema points for this helmet liner region are shown on FIG. 8B asPB1-PBX. Not all boundary points are shown to prevent crowding of thedrawing. FIGS. 8A and 8B include selected point based on cranialfeatures of the mesh of FIG. 7A.

FIG. 4 illustrates a representative graphical user interface (GUI) menu400 for selecting pilot flight equipment (PFE). The graphical userinterface (GUI) menu 400 may allow a user to select which PFE is neededby the pilot as part of the PFE&SC 120. The menu and options available,along with the output from each, are custom to the aircraft supported bythis system. The GUI 400 may allow the user to select the communication,video, and data cables on row 402. For example, this selection mayresult in a specified assembly length and cable routing after processingthe scan of the subject. The row 404 may allow the user to select thevisor(s). The output of this selection, in some embodiments, may be a 3Dmodel file of the required visor if not a printed visor from a CAMdevice. The row 406 may allow the user to select an oxygen mask. In someembodiments, this may be the selection of a standard size, or it may bea fully custom 3D printed oxygen mask based on one or more of the user'snose size, bridge of the nose, chin, lips, and cheek bones. The row 408may allow the user to select an oxygen hose. Similar to the electroniccables 402, this may result in a specified assembly length and hoserouting after processing the scan of the subject. The length of theoxygen hose may be based on the measured distance from the oxygen maskto the oxygen supply source. The row 410 may allow the user to selectthe helmet assembly. The output of this selection may be an entirely 3Dprinted custom helmet, or it may result in a specified size from thestandard helmet sizes available. The row 412 may allow the user toselect the helmet protective liner(s). This may be a single helmetliner, or multiple, as required by the helmet design and PFE assemblyprocess.

FIG. 5A illustrates a first helmet liner 500A having liner parts 505 and510. Specifically, liner part 505 may be for the crown while liner part510 may be for the brow. In this view, the crown liner part 505 and browliner part 510 are shown separate liners. In lieu of a seam, the linersmay also be integrated. As will be readily seen based on the descriptionherein, the liner parts 505 and 510 are customized for the subject'scranial features relative to a candidate helmet from a plurality ofhelmets. The first helmet liner 500A may be configured as an energyliner having a certain thickness that fits within the helmet.

FIG. 5B illustrates a second helmet liner 500B. The second helmet liner500B may be a comfort liner. The second helmet liner 500B may include aliner tabs 517A and 517B. The second helmet liner 500B includes linerbody 516. The second helmet liner 500B may include an anti-ruck tab 518.The liner body 516 may include a brim 519. For example, the helmet mayinclude comfort liner retaining clips (not shown) to secure the liner500B via the liner tabs 517A. The comfort liner 500B may include othercustom features and contours based on helmet features. The placement ofthe tabs 517A and 517B may be determined based on the helmet candidate.Likewise, other custom features such as the anti-ruck tab 518 may bedesigned and dimensioned based on the helmet candidate.

FIG. 5C, illustrates a side view 500C, of a pilot helmet 520 with visor525 and oxygen mask 530. The helmets 520 may be available in a pluralityof sizes. By way of non-limiting example, helmets may be available assmall, medium, large and extra-large. The oxygen mask 530 may becustomized for the facial features of the subject relative to thehelmet, as will be described in more detail. The oxygen mask hose 535may be customized based on the subject's anatomy. The oxygen mask hose535 may be a function of measurements obtained in block 206A of FIG. 2A.

FIG. 11 illustrates a mesh 1100 with oxygen mask landmark points (OMLP)depicted for generating an oxygen mask 530 (FIG. 5B). By way ofnon-limiting example, these landmarks may include cheek bones 716, facewidth, chin 720, nose 718 and nose bridge 719. The face features mayalso include the mouth/lips 722. These features may be used to develop apattern for the oxygen mask 530. A side view of the finished oxygen maskdesign relative to the face is shown in FIG. 5C. The mask 3D model wouldbe generated in a similar manner as the helmet liners. The meshsub-region (not shown) of the oxygen mask would be generated such thatextrema boundary points would be mapped using these OMLP. Additionally,fasteners and other features (e.g., breathing hose attachment,exhalation valve) of the oxygen mask 530 would be generated and includedin the 3D digital model according to the aircraft's requirements. Theoxygen mask may require connectors for attachment to the helmetcandidate. Thus, the oxygen mask pattern would include any connectorpoints, loops, or other means to fasten, strap or attach the mask to thehelmet candidate.

FIG. 12 illustrates a graphical user interface (GUI) 1200 for selectingbelow the neck pilot flight equipment and suit. On row 1202, the usermay select a full coverage lower G-force garment. On row 1204, the usermay select a sleeveless flight jacket. On row 1206, the user may selecta coverall such as a lightweight coverall. On row 1208, the user mayselect a sleeved flight jacket. On row 1210, the user may select acold-water immersion garment. On row 1212, the user may selectcold-water immersion garment socks. On row 1214, the user may select anarm restraint extension lines. On row 1216, the user may select acooling garment. On row 1218, the user may select a skeletal lower Ggarment. On row 1220, the user may select a thermal protective layer.

The selection boxes 1240 may be used to individually select the garmentsof choice and particularly the garment layers. Based on the selectedboxes 1240, the pilot flight garment customizer module 330 may produceone or more customized patterns based on the outer PFG layers. The pilotflight garment customizer module 330 may produce one or more customizedpatterns of inner layers of the PFG relative to the adjacent layers ofgarments and the thickness of the materials used to manufacture thegarment.

Computational Hardware Overview

FIG. 13 is a block diagram that illustrates a computer system 1300(i.e., computing device 150) upon which an embodiment may be implementedor employed. The terms computing system and computer system are usedinterchangeably herein. Computer system 1300 includes a communicationmechanism such as a bus 1310 for passing information between otherinternal and external components of the computer system 1300.Information is represented as physical signals of a measurablephenomenon, typically electric voltages, but including, in otherembodiments, such phenomena as magnetic, electromagnetic, pressure,chemical, molecular atomic and quantum interactions. For example, northand south magnetic fields, or a zero and non-zero electric voltage,represent two states (0, 1) of a binary digit (bit). Other phenomena canrepresent digits of a higher base. A superposition of multiplesimultaneous quantum states before measurement represents a quantum bit(qubit). A sequence of one or more digits constitutes digital data thatis used to represent a number or code for a character. In someembodiments, information called analog data is represented by a nearcontinuum of measurable values within a particular range. Computersystem 1300, or a portion thereof, constitutes a means for performingone or more blocks of one or more methods described herein. Thus, thecomputer system is a special purpose computer system.

A sequence of binary digits constitutes digital data that is used torepresent a number or code for a character. A bus 1310 includes manyparallel conductors of information so that information is transferredquickly among devices coupled to the bus 1310. One or more processors1303 for processing information are coupled with the bus 1310. Aprocessor 1303 performs a set of operations on information. The set ofoperations include bringing information in from the bus 1310 and placinginformation on the bus 1310. The set of operations also typicallyinclude comparing two or more units of information, shifting positionsof units of information, and combining two or more units of information,such as by addition or multiplication. A sequence of operations to beexecuted by the processor 1303 constitutes computer instructions. Agraphics processing unit (GPU) 1350 may be coupled to bus 1310.

Computer system 1300 also includes a memory 1304 coupled to bus 1310.The memory 1304, such as a random access memory (RAM) or other dynamicstorage device, stores information including computer instructions. Thememory 1304 may also include dynamic memory which allows informationstored therein to be changed by the computer system 1300. RAM allows aunit of information stored at a location called a memory address to bestored and retrieved independently of information at neighboringaddresses. The memory 1304 is also used by the processor 1303 to storetemporary values during execution of computer instructions. The computersystem 1300 also includes a read only memory (ROM) 1306, non-volatilepersistent storage device or static storage device coupled to the bus1310 for storing static information, including instructions, that is notchanged by the computer system 1300. The ROM 1306 may be a securebyte-addressable memory (storage) device or a direct-access for files(DAX) memory device. The bus 1310 may also have coupled thereto otherstorage devices including a non-volatile (persistent) storage device,such as a magnetic disk or optical disk, for storing information,including instructions, that persists even when the computer system 1300is turned off or otherwise loses power.

Information, including instructions, is provided to the bus 1310 for useby the processor from an external input device 1313, such as a keyboardcontaining alphanumeric keys operated by a human user, or a sensor. Asensor detects conditions in its vicinity and transforms thosedetections into signals compatible with the signals used to representinformation in computer system 1300. Other external devices coupled tobus 1310, used primarily for interacting with humans, include a displaydevice 1314, such as a cathode ray tube (CRT) or a liquid crystaldisplay (LCD), light emitting diode (LED) displays, for presentingimages, and a pointing device 1316, such as a mouse or a trackball orcursor direction keys, for controlling a position of a small cursorimage presented on the display device 1314 and issuing commandsassociated with graphical elements presented on the display 1314. Theprocessor may be coupled to peripheral devices, such as the CAM device140A or 140B, using peripheral drivers. The processor is configured toperform one or more blocks of the method of FIG. 6 and part of thecustomizer module 320.

In the illustrated embodiment, special purpose hardware, such as anapplication specific integrated circuit (IC) 1330, may be coupled to bus1310. The special purpose hardware may be configured to performoperations not performed by processor 1303 quickly enough for specialpurposes. Examples of application specific ICs include graphicsaccelerator cards for generating images for display device 1314,cryptographic boards for encrypting and decrypting messages sent over anetwork, speech recognition, and interfaces to special external devices,such as robotic arms and scanning equipment that repeatedly perform somecomplex sequence of operations that are more efficiently implemented inhardware.

Computer system 1300 also includes one or more instances of acommunications interface 1370 coupled to bus 1310. Communicationinterface 1370 provides a two-way communication coupling to a variety ofexternal devices that operate with their own processors, such asprinters, scanners and external disks.

The communication interface 1370 may receive images from a digitalscanner 110. Pointing device 1316, input device 1313 and display device1314 may be associated with host computer 1382.

In general, the computer system 1300 through the communication interface1370 may be coupled with a network link 1378 that is connected to alocal network 1380 to which a variety of external devices with their ownprocessors are connected. In some embodiments, the local network 1380may be a private network and may include wired and/or wirelesscommunications. For example, communication interface 1370 may be aparallel port or a serial port or a universal serial bus (USB) port on apersonal computer. In some embodiments, communications interface 1370 isan integrated services digital network (ISDN) card or a digitalsubscriber line (DSL) card or a telephone modem that provides aninformation communication connection to a corresponding type oftelephone line. In some embodiments, a communication interface 1370 maybe a cable modem that converts signals on bus 1310 into signals for acommunication connection over a coaxial cable or into optical signalsfor a communication connection over a fiber optic cable. As anotherexample, communications interface 1370 may be a local area network (LAN)card to provide a data communication connection to a compatible LAN,such as Ethernet. Wireless links may also be implemented. Carrier waves,such as acoustic waves and electromagnetic waves, including radio,optical and infrared waves travel through space without wires or cables.Signals include man-made variations in amplitude, frequency, phase,polarization or other physical properties of carrier waves. For wirelesslinks, the communications interface 1370 sends and receives electrical,acoustic or electromagnetic signals, including infrared and opticalsignals, that carry information streams, such as digital data.

The term computer-readable medium is used herein to refer to any mediumthat participates in providing information to processor 1303, includinginstructions for execution. Such a medium may take many forms,including, but not limited to, non-volatile media, volatile media andtransmission media. Non-volatile media include, for example, optical ormagnetic disks, such as storage device. Volatile media include, forexample, dynamic memory 1304. Transmission media include, for example,coaxial cables, copper wire, fiber optic cables, and waves that travelthrough space without wires or cables, such as acoustic waves andelectromagnetic waves, including radio, optical and infrared waves. Theterm computer-readable storage medium is used herein to refer to anymedium that participates in providing information to processor 1303,except for transmission media.

Common forms of computer-readable media include, for example, a floppydisk, a flexible disk, a hard disk, a magnetic tape, or any othermagnetic medium, a compact disk ROM (CD-ROM), a digital video disk (DVD)or any other optical medium, punch cards, paper tape, or any otherphysical medium with patterns of holes, a RAM, a programmable ROM(PROM), an erasable PROM (EPROM), a FLASH-EPROM, or any other memorychip or cartridge, a carrier wave, or any other medium from which acomputer can read. The term non-transitory computer-readable storagemedium is used herein to refer to any medium that participates inproviding information to processor 1303, except for carrier waves andother signals.

Logic encoded in one or more tangible media includes one or both ofprocessor instructions on a computer-readable storage media and specialpurpose hardware, such as ASIC 1330. Network link 1378 typicallyprovides information communication through one or more networks to otherdevices that use or process the information. For example, network link1378 may provide a connection through a private or local network 1380 toa host computer 1382, such as a secure host computer. For example, insome embodiments, the pilot may be located at the host computer 1382.Thus, the user interfaces referenced in FIG. 13 , may be located withthe host computer 1382.

In some embodiments, the computer system 1300 may connect to equipment1384 operated by an Internet Service Provider (ISP) or Intranet ServiceProvider. ISP equipment 1384 in turn provides data communicationservices through the public, world-wide packet-switching communicationnetwork of networks now commonly referred to as the Internet 1390 oralternately over an Intranet. A computer called a server 1393 connectedto the Internet or Intranet provides a service in response toinformation received over the Internet or Intranet. For example, server1393 provides information representing video data for presentation atdisplay 1314 or the server may receive information representing videodata.

The embodiments related to the use of computer system 1300 forimplementing the techniques described herein. According to oneembodiment, those techniques are performed by computer system 1300 inresponse to processor 1303 executing one or more sequences of one ormore instructions contained in memory 1304 to form a computer programproduct. Such instructions, also called software and program code, maybe read into memory 1304 from another computer-readable medium such asstorage device 1308. Execution of the sequences of instructionscontained in memory 1304 causes processor 1303 to perform one or more ofthe method blocks described herein. In alternative embodiments,hardware, such as application specific integrated circuit 1330, may beused in place of or in combination with software to implement theembodiments. Thus, embodiments are not limited to any specificcombination of hardware and software.

Computer program code for carrying out operations described above may bewritten in a variety of programming languages, including but not limitedto a high-level programming language, such as without limitation, C orC++, for development convenience. In addition, computer program code forcarrying out operations of embodiments described herein may also bewritten in other programming languages, such as, but not limited to,interpreted languages. The program code may include hardware descriptionlanguage (HDL) or very high speed integrated circuit (VHSIC) hardwaredescription language, such as for firmware programming. Some modules orroutines may be written in assembly language or even micro-code toenhance performance and/or memory usage. It will be further appreciatedthat the functionality of any or all of the program modules may also beimplemented using discrete hardware components, one or more applicationspecific integrated circuits (ASICs), or a programmed Digital SignalProcessor (DSP) or microcontroller. A code in which a program of theembodiments is described can be included as a firmware in a RAM, a ROMand a flash memory. Otherwise, the code can be stored in anon-transitory, tangible computer-readable storage medium such as amagnetic tape, a flexible disc, a hard disc, a compact disc, aphoto-magnetic disc, a digital versatile disc (DVD) or the like.

The signals transmitted over network link 1378 and other networksthrough communications interface 1370, carry information to and fromcomputer system 1300. Computer system 1300 can send and receiveinformation, including program code, through the networks 1380, 1390among others, through network link 1378 and communications interface1370. In an example using the Internet 1390, a server 1392 transmitsprogram code for a particular application, requested by a message sentfrom computer 1300, through Internet 1390, ISP equipment 1384, localnetwork 1380 and communications interface 1370. The received code may beexecuted by processor 1303 as it is received or may be stored in storagedevice 1308 or other non-volatile storage for later execution, or both.In this manner, computer system 1300 may obtain application program codein the form of a signal on a carrier wave.

Various forms of computer readable media may be involved in carrying oneor more sequence of instructions or data or both to processor 1303 forexecution. For example, instructions and data may initially be carriedon a magnetic disk of a remote computer such as host computer 1382. Theremote computer loads the instructions and data into its dynamic memoryand sends the instructions and data over a telephone line using a modem.A modem local to the computer system 1300 receives the instructions anddata on a telephone line and uses an infra-red transmitter to convertthe instructions and data to a signal on an infra-red a carrier waveserving as the network link 1378. An infrared detector serving ascommunications interface 1370 receives the instructions and data carriedin the infrared signal and places information representing theinstructions and data onto bus 1310. Bus 1310 carries the information tomemory 1304 from which processor 1303 retrieves and executes theinstructions using some of the data sent with the instructions. Theinstructions and data received in memory 1304 may optionally be storedon storage device 1308, either before or after execution by theprocessor 1303.

The memory 1304 may have stored thereon applications implemented assoftware or computer instructions. The applications when executed by theprocessor 1303 may perform one or more functions and steps as describedherein.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which embodiments belongs. It will befurther understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the relevant art andwill not be interpreted in an idealized or overly formal sense unlessexpressly so defined herein.

In particular, unless specifically stated otherwise as apparent from thediscussion, it is appreciated that throughout the description,discussions utilizing terms such as “processing” or “computing” or“calculating” or “determining” or “displaying” or the like, refer to theaction and processes of a computer system, or similar electroniccomputing device, that manipulates and transforms data represented asphysical (electronic) quantities within the computer system's registersand memories into other data similarly represented as physicalquantities within the computer system memories or registers or othersuch data storage, transmission or display devices.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting. As used herein, thesingular forms “a,” “an,” and “the” are intended to include the pluralforms as well, unless the context clearly indicates otherwise.Furthermore, to the extent that the terms “including,” “includes,”“having,” “has,” “with,” or variants thereof are used in either thedetailed description and/or the claims, such terms are intended to beinclusive in a manner similar to the term “comprising.” Moreover, unlessspecifically stated, any use of the terms first, second, etc., does notdenote any order or importance, but rather the terms first, second,etc., are used to distinguish one element from another.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which embodiments of the inventionbelongs. It will be further understood that terms, such as those definedin commonly used dictionaries, should be interpreted as having a meaningthat is consistent with their meaning in the context of the relevant artand will not be interpreted in an idealized or overly formal senseunless expressly so defined herein.

While various disclosed embodiments have been described above, it shouldbe understood that they have been presented by way of example only, andnot limitation. Numerous changes, omissions and/or additions to thesubject matter disclosed herein can be made in accordance with theembodiments disclosed herein without departing from the spirit or scopeof the embodiments. Also, equivalents may be substituted for elementsthereof without departing from the spirit and scope of the embodiments.In addition, while a particular feature may have been disclosed withrespect to only one of several implementations, such feature may becombined with one or more other features of the other implementations asmay be desired and advantageous for any given or particular application.Furthermore, many modifications may be made to adapt a particularsituation or material to the teachings of the embodiments withoutdeparting from the scope thereof.

Further, the purpose of the foregoing Abstract is to enable the U.S.Patent and Trademark Office and the public generally and especially thescientists, engineers and practitioners in the relevant art(s) who arenot familiar with patent or legal terms or phraseology, to determinequickly from a cursory inspection the nature and essence of thistechnical disclosure. The Abstract is not intended to be limiting as tothe scope of the present disclosure in any way.

Therefore, the breadth and scope of the subject matter provided hereinshould not be limited by any of the above explicitly describedembodiments. Rather, the scope of the embodiments should be defined inaccordance with the following claims and their equivalents.

We claim:
 1. A system comprising: a scanner to scan a subject; and acomputer having at least one processor and tangible, non-transitorycomputer readable medium having program instructions which when executedto cause the at least one processor to: receive, from the scanner,digital three-dimensional (3D) digital surface model (DSM) scan datarepresentative of the surface of the subject in a computational geometryformat; recognize anatomical features on the 3D digital surface; createa closed volume within and between a DSM sub region and a surface offsetfrom the DSM sub region, the closed volume being representative of asolid 3D pilot flight equipment; read and store body measurement datafrom the DSM scan data; use the body measurement data to define at leastone of length, marking, or retention details for the connecting cablesthat are attached to the subject during flight operations, theconnecting cables comprising at least one of communication, video, ordata cables configured to transmit data from flight equipment to anaircraft; and cause a computer-aided manufacturing (CAM) device tomanufacture the solid 3D pilot flight equipment based on the formeddigital data representative of the solid 3D pilot flight equipment. 2.The system of claim 1, wherein the at least one processor is configuredto create the surface offset from the sub region, and wherein creatingthe surface offset from the sub region comprises defining a thickness ofthe solid 3D pilot flight equipment.
 3. The system of claim 1, whereincreating the closed volume comprises integrating, by the at least oneprocessor, internal and external features in the formed digital datarepresentative of the solid 3D pilot flight equipment.
 4. The system ofclaim 1, wherein the at least one processor is further configured to:determine, based on a user selection, a type of solid 3D pilot flightequipment; and responsive to the determination, automatically select adesign of the solid 3D pilot flight equipment.
 5. The system of claim 4,wherein the user selection includes at least one of a pilot's helmetliner, a breathing mask, or body armor.
 6. The system of claim 1,wherein the CAM device is a 3D printer.
 7. The system of claim 1,wherein the at least one processor is further configured to prescribealterations to prescribed garment sizes based on the body measurementdata responsive to a comparison of a computed fit of the prescribedgarment sizes to the body measurement data.
 8. A system comprising: ascanner to scan a subject; and a computer having at least one processorand tangible, non-transitory computer readable medium having programinstructions which when executed to cause the at least one processor to:receive, from the scanner, digital three-dimensional (3D) digitalsurface model (DSM) scan data representative of the surface of thesubject in a computational geometry format; receive an inputcorresponding to a type of the solid 3D pilot flight equipment;recognize anatomical features on the 3D digital surface based on thetype of the solid 3D pilot flight equipment; create a closed volumewithin and between a DSM sub region and a surface offset from the DSMsub region, the closed volume being representative of a solid 3D pilotflight equipment; prescribe alterations to prescribed garment sizes forthe subject based on body measurement data responsive to a comparison ofa computed fit of the prescribed garment sizes to the body measurementdata, wherein the body measurement data is determined from the DSM scandata; and cause a computer-aided manufacturing (CAM) device tomanufacture the solid 3D pilot flight equipment based on the formeddigital data representative of the solid 3D pilot flight equipment. 9.The system of claim 8, wherein the at least one processor is furtherconfigured to store the DSM sub region, the DSM sub region being definedby the anatomical features as a non-manifold 3D surface model.
 10. Thesystem of claim 8, wherein the type of 3D pilot flight equipment is ahelmet liner and wherein the recognized anatomical features include anear, a brow, and a nape.
 11. The system of claim 8, wherein the type of3D pilot flight equipment is an oxygen mask and wherein the recognizedanatomical features include a face width, a chin, a nose, and cheekbones.
 12. The system of claim 8, wherein the type of 3D pilot flightequipment is body armor and wherein the recognized anatomical featuresinclude a head contour and one or more regions of a torso and legs. 13.A method comprising: receiving, from a scanner, digitalthree-dimensional (3D) digital surface model (DSM) scan datarepresentative of the surface of a subject in a computational geometryformat; recognizing one or more anatomical features on the 3D surfacemodel; creating a closed volume within and between a DSM sub region andan offset surface representative of a solid 3D pilot flight equipment;reading and storing body measurement data from the DSM scan data;defining, based on the body measurement data from the DSM scan data,length, marking, and retention details for the interconnecting cablesthat are attached to the subject during flight operations, theinterconnecting cables comprising at least one of communication, video,or data cables being configured to transmit data from flight equipmentto an aircraft; and causing a computer-aided manufacturing (CAM) deviceto manufacture the solid 3D pilot flight equipment based on the formeddigital data representative of the solid 3D pilot flight equipment. 14.The method of claim 13, further comprising: determining, based on a userinput, a type of the solid 3D pilot flight equipment type; andresponsive to the determination, automatically selecting a design of thesolid 3D pilot flight equipment.
 15. The method of claim 13, whereinduring the creating of the offset surface from the sub region, at leastone processor further to define the thickness of the solid 3D pilotflight equipment.
 16. The method of claim 13, wherein the user inputcomprises at least one of a pilot's helmet liner, a breathing mask, or aprotective body armor layer.
 17. The method of claim 13, furthercomprising: printing the formed digital data representative of the solid3D pilot flight equipment, wherein the CAM device is a 3D printer. 18.The method of claim 13, further comprising prescribing a size associatedwith the solid 3D pilot flight equipment based on the body measurementdata.
 19. The method of claim 18, further comprising: prescribing one ormore alterations to the size associated with the solid 3D pilot flightequipment based on a comparison of the prescribed size to the bodymeasurement data.
 20. The method of claim 13, wherein theinterconnecting cables are further defined based on at least one of acockpit seat size or a seat location.